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Purpose of TFAR	Approval	Approval / feedback	Warranty	Type of TFAR	Truck Chassis

Subject/Complaint
The vehicle reported Starting problem.
Report Number	692100-2025-70361	Report Date	31-Jul-2025	Prepared By	vkchaubey1
Dealer ID	692100	Dealer Name	VSPC-Jaipur
Customer Name	Hari Ram Godara JV	Customer Contact Person	bajarng ji
Workshop/Site-Location	RSMM JHAMARKOTRA UDAIPUR	Customer Contact Number	9660620064
Chassis Model with Axle Configuration	FM(4) 460 8x4 BS6	Body CuM & Application	20.3 cum RB HYVA
Chassis No	8-985009	Reg. Number		Date of Delivery	17-Oct-2023
Date of failure	28-Jul-2025	Repair Order No.	4043	Repair Date
Failure Mileage kms	153599	Age in Months	22	Engine Hrs.	9717
Function Group	2111	Causal Part No.	23110668	Description	Engine Head Assembly
Defect Code Group	8 BREAKAGE	Defect Code	82-MATERIAL CRACK
Spare parts warranty	No	Spare parts invoice details		Spare parts fitment date	0000-00-00
Driveline Warranty	Yes	GDR No

Repair Estimate Summary

Material Cost	775323.28	Labor Cost	15396.41	Other Cost	20561.50

Road Details

Type of road surface (Asphalt, Soil Gravel, Sharp stones etc.	SOIL
Dust Condition (Heavy Slight, etc.,)	SLIGHT
Approx. Gradient of the Road (required for engine and wheel Hub failures	1:16
Undulation on the Road( Heavy,Slight, Lot of pot holes, large Bumps, etc.)	SLIGHT
Was the vehicle travelling Uphill or Downhill (required for engine and wheel hud failures	NA

Load Details

Type of load carried	OVER BURDEN	Permitted Technical GCW	49	GCW during failure	NA

Available information on the load types and GCW's handled by the vehicle earlier which could have caused the failure

Aggregate details

Details of the concerned failed Aggregate ( Engine, Gearbox, Rear Axle, Diffeerential, Rear Axle, Diff. carrier, steering gear, Turbocharger, Superstructure Hydraulic parts etc.)
Aggregate	xx	Aggregate Part No.	xx	Aggregate Sr. No.	xx

Interview with the Driver ( Applicable for all driveline related failures)

Driver Name	shyam singh	Training details on the related variant	Trained By VECV.

Drivers description on the happening of the failure:

The vehicle reported Starting problem.

Technical Explination of complaint (Dealer comment):

* Upon receiving the complaint of the engine not starting, the following diagnostic steps were carried out:

# Verified battery voltage: found at 24.5V, which is within the acceptable range.
# Electrical lines and power supply circuits were checked and found to be intact.
# Suspecting a coolant-related issue, the coolant level was checked and found to be low.
# The coolant was topped up to the recommended level.
# A thorough inspection of the coolant circuit, hoses, and joints was conducted — no external leakages were detected.
# Despite the coolant refill, the vehicle still did not start.
# Manual cranking was attempted using the cranking tool — engine rotation was abnormally hard, indicating possible internal resistance.
# Connected the VTT to check for fault codes and perform GD.
# Found the following inactive DTCs:
P021700 – Engine Coolant Over Temperature Condition.
P029800 – Engine Oil Over Temperature
# Performed relevant engine-related diagnostic tests. No electrical faults were indicated, but mechanical resistance was suspected.
# Based on symptoms and test outcomes, a decision was taken to dismantle the engine cylinder head for further investigation.
# After the removal of the cylinder head, visible cracks were observed in multiple intake ports.
# Inlet ports of cylinders 2, 3, 4, and 5 were found to be cracked.
# No other abnormalities were found in the combustion chamber or liners at the time of inspection.

Fault codes registered in vehicle (Including Active and Inactive Faults)

Inactive fault codes- P021700, P029800

Is the causal part a recently modified one	Yes

If Yes, kindly provide more details about the modification:

Causal Part No. 23110668 mentioned on the failed part is NS, and the new part number is 23762967.

Is this a repeat failure	No	Is yes, provide relavant details

Relavant Argus No. If any		Relavant DQR No. If any		Relavant MQR No. If any

Relavant QJ No. If any

Affected Vehicle details

Chassis No	Model	Body No	Date of Delivery	Date of Failure	Mileage Kms	Engine hrs	Parts Sl.no
--	--	--	--	--	--	--	--

Area(Photos Where required/Applicable)

Photo Area	Description/Remarks
	VDN-7
	Chassis No.: 8-985009
	Chassis No.: 8-985009
	KMs-153599 Hours-9717
	DTC readout in VTT.
	GD
	As per GD checking step by step.
	As per GD checking step by step.
	As per GD checking step by step.
	As per GD checking step by step.
	As per GD checking step by step.
	As per GD checking step by step.
	As per GD checking step by step.
	As per GD checking step by step.
	As per GD checking step by step.
	Fuel consumption data.
	Engine statistics data, engine oil pressure bar graph.
	Engine statistics data, engine oil temperature bar graph.
	Engine statistics data, engine oil temperature bar graph.
	Engine statistics data, Vehicle speed bar graph.
	Engine statistics data, engine coolant temperature bar graph.
	Full long shot view of the failed engine head.
	Causal Part No.: 23110668 Serial No.: 240871441
	Cylinder liner, piston condition after removal of the head. Found coolant inside.
	Cylinder Liner No. 1 OK
	Cylinder Liner No. 2 OK
	Cylinder Liner No. 3 OK
	Cylinder Liner No. 5 OK
	Cylinder Liner No. 6 OK
	Head was cracked pn 2nd no. inlet valve side.
	Head was cracked pn 3rd no. inlet valve side.
	Head was cracked pn 4th no. inlet valve side.
	Head was cracked pn 5th no. inlet valve side.

Probable Cause of Failure

Suspected that cylinder head cracked due to material quality issue

Corrective Action/Suggestions

Need to replace the failed parts.

Service and Repair History of the vehicle (Relevant to the failure)

S.No.	Job Card No.	Date	Mileage Kms	Engine Hrs.	Job carried out	Remarks
1	3159	20-Jun-2024	48906	3180	Engine replace	TFAR Number-692100-2024-56709
2	xx	02-Aug-2024	62248	4050	basic service done
3	xx	01-Oct-2024	74239	4865	Annual service
4	3419	22-Oct-2024	82662	5260	Oil pump replace	Under caimpaign
5	xx	03-Dec-2024	93694	5930	basic service
6	xx	08-Jan-2025	103333	6565	basic service
7	xx	14-Feb-2025	114464	7240	annual service
8	xx	24-Mar-2025	125056	7920	basic service and coolant replace
9	xx	07-May-2025	135762	8598	basic service
10	xx	16-Jun-2025	1463112	9272	basic service

Repair Estimate

Material Cost

S.No.	Part no	Description	Qty	Unit Price	Net Price	GST %	GST Amt.	Net Price including GST	Pay code
1	23762967	Engine Head Assembly	1	500672	500,672.00	18	90,120.96	590,792.96	9
2	22164943	DE-CARBONIZING KIT	1	61894.16	61,894.16	18	11,140.95	73,035.11	9
3	23764231	PISTON RING KIT	6	2791.54	16,749.24	18	3,014.86	19,764.10	9
4	470922	SEALING RING	3	478.93	1,436.79	18	258.62	1,695.41	9
5	470190	SEALING RING	6	460	2,760.00	18	496.80	3,256.80	9
6	270950	GASKET KIT	3	4058.59	12,175.77	18	2,191.64	14,367.41	9
7	21503575	Sealing Ring	1	993.19	993.19	18	178.77	1,171.96	9
8	21613426	thermostat	1	4613.24	4,613.24	18	830.38	5,443.62	9
9	20551483	sealing ring	2	1067.65	2,135.30	18	384.35	2,519.65	9
10	22794275	CYLINDER HEAD KIT	1	38121.23	38,121.23	18	6,861.82	44,983.05	9
11	21294062	GASKET	1	4891.51	4,891.51	18	880.47	5,771.98	9
12	23759508	OIL FILTER KIT	2	2345.43	4,690.86	18	844.35	5,535.21	9
13	984050	HEXAGON NUT	8	121.78	974.24	18	175.36	1,149.60	9
14	995906	HEXAGON SCREW	8	405.1	3,240.80	18	583.34	3,824.14	9
15	22275838	SEALING RING	2	383.2	766.40	18	137.95	904.35	9
16	21092243	SEALING RING	2	469.46	938.92	18	169.01	1,107.93	9
Total					657,053.65	Total		775,323.31

Labour cost

S.No.	Operation No	Description	Qty.	Unit Price	Net Price	GST %	GST Amt.	Net Price including GST	Pay code
1	21126-2	Cylinder head, replace	12.2	855	10,431.00	5	521.55	10,952.55	09
2	20007-3	Engine protection data	0.2	855	171.00	5	8.55	179.55	09
3	21305-3	Piston rings, replace (3)	1.35	855	1,154.25	5	57.71	1,211.96	09
4	21311-3	Cylinder liners and pistons, replace (3)	3.4	855	2,907.00	5	145.35	3,052.35	09
Total					14,663.25	Total		15,396.41

Other cost

S.No.	Description	Qty.	Unit Price	Net Price	GST %	GST Amt.	Net Price including GST	Pay code
1	OL 85153938 ENGINE OIL VDS5 210 LTR	35	308.72	10,805.20	5	540.26	11,345.46	9
2	IN2 24754666 COOLANT-VCS2 210L	42	183.59	7,710.78	5	385.54	8,096.32	9
3	OL 1161995 Oil-Power Steering	5	213.28	1,066.40	5	53.32	1,119.72	9
Total				19,582.38	Total		20,561.50

Total cost of Repair( Material, Labor and Other cost)	811,281.22

Any Local solution or suggestion from the Field team for Prevention/ Quick resolution of Complaint

ANNEXURES (Select the annexure attached)

17012-3 VCADS Pro Error Codes Test		Compulsory for all failures having fault codes
17034-3 Vehicle information test		Compulsory for all failures having fault codes
28486-3 Sensor Values History Report		Compulsory for all failures related with the engine
20007-3: Engine protection data
28407-3 Sensor Values, Monitoring
20005-3: Fuel consumption data
28108-8 Engine ECU, check		Compulsary for all failures related with the engine ECU
PDF file of the Repair history of the vehicle in LDS– complete		Optional
Scan or Fax copy of the Last BS or AS (as applicable) checksheet		Compulsary
Completely filled checksheets and Protocols as given in Impact/FAG in YVD for the complaint		Compulsary

Additional Attachments

S.No.	Attatchemnt
--	--

Oil & Fuel Sample Test Reports (Compulsory for all major engine related failures):

Sample Date		Sent to ELF Mumbai

Dispatch Details of Failed Parts( Mandatory for critical failures/failures related to safety/failures related to performance)

Docket No		Dispatch Date		Courier Name		Transporter Veh No.

Present Status of the vehicle

Present Status	Breakdown	Reason	Waiting for Decision.

Comments

S.No.	Remarks	By	Date & Time	TFAR Status
1	Dear Sir, Please find the details of cylinder head failure case	vkchaubey1	2025-07-31 18:06:44	TFAR RAISED
2	For corrections:- - Service details. - Previous repair history. - Probable cause of failure.	vkchaubey1	2025-08-04 10:07:04	QUERY RAISED
3	Service history and probable cause is mentioned	vkchaubey1	2025-08-04 14:03:55	REPLY TO QUERY
4	Dear Jacob, An engine head crack case has been reported at Hari Ram Godara J.V., Jhamar Kotra, Udaipur site, with the vehicle currently at 9717 engine hours. Requesting your validation for warranty consideration. Kindly suggest.	vkchaubey1	2025-08-04 15:11:43	TFAR FORWARDED
5	Hello All This case is forwarded to VTC for approval. Regards Jacob	jmathew1	2025-08-20 10:28:50	AMTS UPDATE
6	Hello Team VTC has rejected this case as the vehicle is utilized beyond the limits. the vehicle is carrying heavier load (more than rated capacity) for 34% of the time. The vehicle climbs higher gradients for 15% (more than 6% gradient)of the timer. higher utilization will shorten the life of parts. Regards Jacob	jmathew1	2025-08-21 12:08:57	REJECTED